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Open access

D. Szeliga, R. Kuziak, R. Kopp, G. Smyk and M. Pietrzyk

The paper deals with the problem of identification of microstructure evolution model on the basis of two-step compression test. Classical interpretation of this test assumes uniform fields of strains, stresses and temperatures in the deformation zone and calculates the coefficients in the model on the basis of force measurements in the second step. In the present paper the inverse approach was applied. Finite element (FE) simulations of the compression test were performed and local values of microstructural parameters were determined accounting for the inhomogeneity of deformation. Objective function was formulated as the Euclid norm for the error between measured and calculated forces for various interpass times. Coefficients in the microstructure evolution model were determined by searching for the minimum of the objective function. Optimized model was validated in simulations of plane strain compression tests.

Open access

J. Kusiak, M. Skóra, Ł. Rauch, D. Szeliga and M. Pietrzyk

Abstract

The development of the best manufacturing technology for fasteners was the subject of this work. Physical and numerical simulations were used to evaluate various technological variants. Possibility of application of new generation bainitic steels was considered, as well. Improvement of exploitation properties was the objective of the optimization having in mind tool wear and manufacturing costs as constraints. Several fasteners were investigated but results for three parts, including Allen screw, screw anchors used to carry concrete plates are presented as a case study. Industrial trials were performed and confirmed correctness of the designed manufacturing technology.

Open access

D. Szeliga, K. Kubiak and J. Sieniawski

Abstract

The analysis of influence of mould withdrawal rate on the solidification process of CMSX-4 single crystal castings produced by Bridgman method was presented in this paper. The predicted values of temperature gradient, solidification and cooling rate, were determined at the longitudinal section of casting blade withdrawn at rate from 1 to 6mm/min using ProCAST software. It was found that the increase of withdrawal rate of ceramic mould results in the decrease of temperature gradient and the growth of cooling rate, along blade height. Based on results of solidification parameter G/R (temperature gradient/solidification rate), maximum withdrawal rate of ceramic mould (3.5 mm/min), which ensures lower susceptibility to formation process of new grain defects in single crystal, was established. It was proved that these defects can be formed in the bottom part of casting at withdrawal rate of 4 mm/min. The increase of withdrawal rate to 5 and 6 mm/min results in additional growth of susceptibility of defects formation along the whole height of airfoil.

Open access

R. Cygan, D. Szeliga, P. Rokicki, J. Sieniawski and J.S. Suchy

Abstract

This paper provides an analysis of experimental research and results of investment casting process. Temperature field in a ceramic mold is one of the problems during numerical simulation. Reducing the costs of production in precision casting involves the reduction of scraps, which is one of the fundamental problems of the foundry industry. Reducing these costs is associated with optimization of precision casting technology of aircraft engines critical parts, including control of the solidification front in thin-walled castings of nickel super alloys cast in a vacuum. It is achieved by changing the geometrical characteristics of the ceramic mold. The results of the tests were used to optimize the industrial production of aircraft components in Precision Foundry of WSK Rzeszów. Temperature distribution gained in the conducted tests allowed verification and optimization of computer simulations.

Open access

P.K. Krajewski, G. Piwowarski, J. Buraś, W.K. Krajewski, P. Rutkowski and D. Szeliga

Abstract

The paper brings results of examinations of main thermo-physical properties of selected Inconel alloys, i.e. their heat diffusivity, thermal conductivity and heat capacity, measured in wide temperature range of 20 – 900 oC. Themathematical relationships of the above properties vs. temperature were obtained for the IN 100 and IN 713C alloys. These data can be used when modelling the IN alloys solidification processes aimed at obtaining required structure and properties as well as when designing optimal work temperature parameters.